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What size tap am I going to need to clean out the threads on the stock EA82 y-pipe? I've got to do two of these things tommorow. I shattered the first one, and took an impact to it. The sensor threads just disintigrated - left all the thread metal in the cat. So I'm going to have to buy a tap for it since my set doesn't go quite that big....

All well and good... until you try to clean galled/welded threads out of that weld-hardened bung. How many modified splugs do you want to wear out in the process? Mine was a (minor) bear to clean out even with the chaser. Me, I am in to "lazy" when I can.

Yeah, I ripped all the threads of of mine... well, it was my bro-in-law's, but now it is mine. EGO sensor came out looking pretty smooth where all of the threads were supposed to be. That was before I read that there was a procedure for removing EGOs (something like: warm engine, turn EGO 1/4 turn, spray on penetrant and go away for 24 hours before turning again).

That's a nice procedure! Too bad the y-pipe isn't on a car yet. ...... and I already tore it out with my impact. Hooray for air! Quicker to cut the thing off, impact it, and then chase the threads. Whole countries have been overthrown in 24 hours.

wonderful timing for this thread, i need to replace my O2 sensor and we have a couple spares at the shop.. now I just need to look up the vehicle whence they came, and see if this matches the subie. thanks guys :- )